When formulating materials to be used as a non-conductive barrier  for high voltages, it is critical to ensure what  they can withstand under various conditions. A material’s ability to resist electrical breakdown, known as its dielectric strength, is one such factor. The ASTM D149 standard is widely used to evaluate this. This test measures the dielectric breakdown voltage and dielectric strength of solid electrical insulating materials.

This test, when used alongside UV aging tests recommended by IEEE 1656, provides manufacturers a comprehensive look into just how well a material can maintain its ability to insulate over time. In this article, we will explore the significance of the ASTM D149 test, the effects of UV aging on dielectric performance, and the importance of conducting electrical insulation testing of ASTM D149 on both virgin and UV-aged materials.

What is ASTM D149 for Dielectric Strength?

The ASTM D149 standard evaluates the dielectric breakdown voltage of solid insulating materials. In other words, ASTM D149 measures how high of voltage a material can withstand before it fails. This test is useful in determining the safety of a material and whether or not it should be used in electrical applications. This test is typically conducted at commercial power frequencies for high voltage insulation testing.

The dielectric strength of a material is measured mainly in two metrics:

• Puncture Voltage (kV): The voltage at which the material breaks down or punctures.
• Volts per Mil (V/mil): The breakdown voltage per unit thickness of the material.

While it is recommended that material be tested at the same thickness as it is on a complete product, you may encounter test results based on material of varying thicknesses. Volts per Mil (V/mil) is an effective metric for evaluating the dielectric strength of insulating materials, indicating how much voltage a material can withstand per unit of thickness. This measurement providing a standardized metric to compare products across manufacturers as it provides a consistent basis for assessment regardless of material thickness. By standardizing how insulation performance is measured, this metric enables clearer, more informed choices in material selection, enhancing both product design and safety protocols.

How to Perform Dielectric Breakdown Test ASTM D149

The ASTM D149 dielectric breakdown test involves placing the material under controlled conditions where increasing voltage is applied until the material punctures. Ideally, this test should be performed on both virgin (unexposed) materials as well as materials that have been subjected to environmental factors, namely UV aging. This helps to simulate real-world conditions and is important to do as the amount of UV exposure a material has endured will affect its durability over time.

Source: MATSUSADA PRECISION

Testing Virgin and UV-Aged Material

The ASTM D149 high voltage electrical test allows for the evaluation of both new and aged materials. When this test is used in conjunction with other standards like IEEE 1656 where materials are subjected to UV exposure, it accurately simulates the durability of materials in real-world conditions. Years of exposure to environmental conditions such as sunlight can degrade dielectric properties. This test is commonly performed after 1,000 hours of UV exposure following ASTM D4329 and G154 guidelines.

Here is an example of how dielectric strength changes after UV aging:

The slight decrease in puncture voltage and volts per mil after 1,000 hours of UV exposure shows that while there is some degradation, the material retains most of its dielectric strength. This provides confidence in the material’s long-term performance in outdoor environments.

Electrical Insulation Testing ASTM D149

High voltage insulation testing is important for many industries, including power utilities. Insulating materials are subject to mechanical stresses, environmental exposure, and high voltage, which means they need to maintain their dielectric strength over time. Along with the dielectric breakdown test, other electrical insulation testing methods such as tensile and impact strength tests are also conducted to assess mechanical properties.

Key mechanical tests that complement dielectric strength testing include:

• ASTM D256 & ASTM D4812: Impact Strength (notched and un-notched)
• ASTM D638: Tensile Strength, Elongation, and Modulus
• ASTM D790: Flexural Strength and Modulus

These tests provide a comprehensive understanding of how well the material will perform under various mechanical and electrical conditions, ensuring long-term reliability.

Understanding ASTM D149 Test Methods for Insulation

ASTM D149 testing involves subjecting materials to a slow, controlled rise in voltage until the dielectric breakdown occurs. The results determine whether the material can be used in demanding environments and applications like electrical utilities. This test is useful to do on insulation materials that must remain intact under extreme conditions.

Are Your Materials Up to Par?

The ASTM D149 standard is a valuable tool for evaluating the long-term performance of electrical insulation materials. ASTM D149 high voltage electrical testing, especially when used in conjunction with UV aging tests provides essential insights into a material’s durability in real-world environments. When evaluating products for installation on your network, take a look at these kinds of test results to determine the potential longevity of your investment.

At Rauckman Utility Products, we pride ourselves on the safety of our electrical materials and are proud to offer electrical insulation materials that meet the highest standards. To learn more or to request a quote, click here and one of our representatives will get in contact with you.

For utilities looking to implement effective wildlife protection solutions, it is essential to understand the quality and durability of the products you are purchasing. Arguably, one of the most effective ways to determine quality is through the use of accelerated Ultraviolet (UV) testing recommended by IEEE 1656. This process simulates the effects of prolonged exposure to sunlight and moisture. By combining accelerated UV aging with other mechanical and material test, it is effective for predicting how products will withstand real-world conditions. By understanding and requesting UV testing results, utilities can ensure they are purchasing higher-quality products that endure the test of time.

Understanding Accelerated UV Testing

Accelerated UV testing, as outlined in the IEEE 1656 Ultraviolet Aging guidelines, involves exposing materials to intensified UV light, which mimics the sun’s ultraviolet rays. This process can simulate years of exposure in a matter of weeks. The test chambers used in this process have UV lamps that replicate the sun’s spectrum.

IEEE 1656 recommends performing UV Aging in a chamber that meets the requirements in ASTM D4329 and performing repeating cycles in accordance with ASTM G154 resulting in a repeating simulation cycle as follows:

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The main goal of UV exposure testing is to identify potential weaknesses in materials that could lead to degradation, such as fading, cracking, or loss of mechanical integrity. This can be measured quantitatively by performing mechanical tests and material tests before and after submitting the material to UV aging. Requiring testing according to this pattering helps utilities evaluate and predict product longevity and performance in real-world environments.

The Benefits of Accelerated UV Testing

1. Enhanced Product Durability

Accelerated UV resistance testing helps confirm products can withstand prolonged exposure to sunlight. This is especially important for products used outdoors in the rigorous environment created by the electrical power grid. UV testing for materials for both barriers and guards is also beneficial. Evaluating according to these standards allows utilities to implement protection with durable products that maintain their appearance and functionality over time.

2. Improved Material Selection

The testing process allows manufacturers to compare different materials and coatings, selecting those that offer the best potential to last in the field. This also encourages manufacturers to be more innovative in developing products and materials that are better suited to withstand the effects of sunlight and weather exposure.

3. Quality Assurance

Accelerated UV testing provides concrete data on how materials will perform under extreme conditions, ensuring your ability to select only the highest quality products. This contributes to grid reliability and improving numbers related to SAIDI and SAIFI. Referring to IEEE 1656 for UV testing helps have an easy and commonly accepted guideline to consistently measure quality across products.

4. Cost Savings

Requiring accelerated UV testing can save significant amounts of money in the long run by identifying potential material failures prior to implementation. By maintaining your ability to invest in quality products, utilities can experience significant cost savings in the long-term by avoiding: (1) the cost of unplanned outages due to subpar protection, (2) the need to replace low quality products after short periods of time, (3) costs related to the safety and lowered customer confidence as a result of unplanned outages.

5. Maintain High Standards

Many industries and other product categories in the power industry have stringent standards for UV resistance, particularly those involving outdoor applications. It is only reasonable that those high standards we apply in other areas should be expected for the products we install on high value equipment. Accelerated UV testing ensures that products meet these regulatory requirements, avoiding potential legal issues and market entry barriers. The IEEE1656 guide is a good reference to act as a guideline in determining whether a product is durable.

UV Aging Real-World Applications

Rauckman Utility Products meet the highest standards of quality and durability. All of our products go through extensive UV testing using sample sizes of product material, exceeding 1000 hours, to verify performance. We perform mechanical and material tests before and after performing accelerated UV aging. This rigorous UV degradation testing ensures that materials can endure prolonged exposure to harsh sunlight without compromising their integrity or functionality. We do this to demonstrate our commitment to quality and durability and to ensure we provide customers with reliable products that withstand real-world conditions.

Conclusion

Accelerated UV testing, as defined by the IEEE 1656 standards for UV testing, is an invaluable tool for utilities aiming to implement high-quality, durable protection products. When you choose Rauckman products, you can trust that they have been tested to the highest UV testing standards for exceptional performance and durability.

Rauckman products are tested to exceed many of the IEEE 1656 recommendations. Contact us today to request a quote or to ask any questions regarding our products.

Flammability is an important factor in the development and testing of products for application on electrical equipment. The IEEE 1656 guide provides a framework for assessing the fire hazards associated with electrical components and offers various testing methods to evaluate their flammability. This article will explore the different flammability testing standards under the IEEE 1656 guide, as well as explore why UL 94 V-0 is considered the gold standard.

Understanding Flammability Testing in IEEE 1656

IEEE 1656 provides guidelines for evaluating the flammability of materials used in electrical equipment. Two primary tests are used to assess the flammability of materials: the horizontal flame test and the vertical flame test.

1. Horizontal Flame Test:

The horizontal flame test evaluates the material’s flammability in a horizontal orientation. The test involves exposing the sample to a flame and observing whether it ignites and how long it continues to burn. This test only measures if the material burns when exposed to a flame. It does not provide insights into how quickly the material can self-extinguish or whether flaming droplets are produced during combustion.

2. Vertical Flame Test:

The vertical flame test is more rigorous and informative compared to the horizontal flame test. In this test, the material sample is held vertically, flammable material is placed underneath the sample, and a flame is applied to the bottom edge. Observations are made on whether the material ignites, the duration it takes to self-extinguish, and the presence of flaming droplets. The vertical flame test offers a more realistic assessment of flammability because it simulates conditions where materials might catch fire from below, a common scenario in real-world applications.

The results of the vertical flame test are categorized into three ratings: V-0, V-1, and V-2. A V-0 rating indicates the highest level of flame resistance, where the material self-extinguishes within 10 seconds, and flaming droplets are not produced. V-1 and V-2 ratings indicate progressively lower levels of flame resistance and longer self-extinguishing times.

Source: ChiuVention

UL V-0 Rating Explained

UL 94 Flame Classification is a standard for determining the flammability of plastic materials used in devices and appliances by assessing their ability to extinguish flames under controlled conditions. The UL 94 V-0 rating is widely regarded as the best indicator of a material’s flammability resistance for wildlife mitigation products. Here’s why:

1. Comprehensive Evaluation:

The vertical flame test, which leads to a UL 94 V-0 rating, provides a comprehensive evaluation of a material’s behavior when exposed to fire. The UL V-0 testing process determines whether the material self-extinguishes quickly and if flaming droplets are produced, this test offers a more thorough understanding of fire hazards compared to the horizontal flame test.

2. Realistic Simulation:

The vertical orientation used in the UL 94 V-0 test simulates real-world fire scenarios more accurately. Fires often start from below and spread upwards, making the vertical flame test more relevant for assessing the safety of materials used in electrical equipment.

3. Highest Safety Standard:

A UL 94 V-0 rating signifies the highest level of flame resistance for flame retardant materials in the IEEE 1656 guide and ensures electrical equipment fire safety. Materials with this rating self-extinguish within 10 seconds and do not produce flaming droplets, significantly reducing the risk of fire spread and secondary ignition. This makes UL V-0 rated plastics ideal for electrical equipment.

Source: Sur-Seal

Ensure Fire Safety Compliance Today

Understanding UL V-0 and other flammability testing methods will help you to ensure electrical equipment safety and reliability. At Rauckman Utility Products, we are proud to offer materials that meet the stringent UL 94 V-0 rating to ensure the highest level of fire safety for our customers. For more information or to place an order click here to get in contact with one of our representatives.